MAGNESIUM ALLOY: AN ENGINEERING MARVEL WHERE EVERY GRAM COUNTS

The Bell V-280 Valor, engineered to fly further and faster than any current rotorcraft, has been selected by the US Army as its next-generation assault aircraft. Developed by Bell Textron, Inc., the V-280 delivers transformational improvements in speed, range and maneuverability. Its emphasis on lightweight construction aligns with the unmanned aircraft market, $15.8 billion in 2025 and projected to reach $22.81 billion by 2030. This reflects a compound annual growth rate (CAGR) of approximately 7.6 percent, according to research and consulting firm Markets and Markets. From here, the sky's the limit!

In an era where every gram can impact speed and performance, particularly in aviation and aerospace, integration of advanced materials and technology is essential. This is why Aero-Magnesium has pioneered the use of Magnesium as a structural material, establishing itself as both a market leader and a center of excellence. Founded in 2005 as an R&D unit, the company has evolved into a specialized Magnesium manufacturing hub, whose mission is to redefine a field once considered niche: production of high-precision Magnesium components for the defense, aerospace and aviation sectors.

Recognized as a pioneer in the field and a leading global center for Magnesium structures and alloy processing, the company has set a new benchmark in application of nature's lightest metallic element. Aero-Magnesium combines deep engineering expertise, proven experience and front-line solutions still in development to advance the frontiers of Magnesium technology.

"With the demand for lightweight, high-performance components becoming paramount, every gram matters," says Aero-Magnesium CEO Yaki Cohen. "That's why we chose magnesium — a metal renowned for its exceptional strength-to-weight ratio — particularly for aircraft and other high-speed machines that must endure extreme loads."

As a certified public accountant, Cohen brings to the company extensive expertise in financial management, project oversight, supply chain operations and strategic planning.

Providing End-to-End Magnesium Solutions
Magnesium has historically received less attention than many other metals. Today, however, it is recognized for enabling engineering solutions that were unattainable only a decade ago. "Magnesium has mechanical properties comparable with Aluminium, but it's 35 percent lighter," explains Cohen. "In the early 2000s, Israel's government issued a call to develop Magnesium technologies, recognizing the metal as one of the country's few natural treasures."

This is where Aero-Magnesium enters, established in Kibbutz Ein Harod Ihud in the Jezreel Valley, where its factory and offices remain. Because of the complexity, high costs and other challenges associated with Magnesium, many industries and researchers struggled to advance the technology, but Aero-Magnesium remained committed. Over the years, it has successfully delivered comprehensive, end-to-end Magnesium solutions for the aerospace, defense and aviation sectors — from sourcing raw materials to providing the completed product, including advanced finishing techniques and surface treatments (coating / painting).

From a Small Production Line to End-to-End Magnesium Solutions Aero-Magnesium's story is that of a small company that, until just two years ago, had only around 40 employees. Recognizing the potential of magnesium alloys, it has transformed into an industrial organization with a strong engineering focus, delivering lightweight technological solutions. Since acquired in early 2024 by the Ricor Group, a leader in vacuum and cryogenic cooling systems, Aero-Magnesium has doubled its workforce to 70 people. Aero-Magnesium operates a modern manufacturing facility featuring advanced engineering infrastructure, a state-of-the-art casting plant, high-precision machining systems, plastic molding technologies (forging), and coating lines that incorporate proprietary Magnesium specific coating processes developed over the past 20 years with a German company - BASF.

"The entire process is driven by innovation and guided by the strictest industrial and environmental standards, including the AS9100 quality management system," says Cohen. "We're committed to delivering components to our partners that meet the highest standards of performance, reliability and durability." The company's services extend beyond production, he continues, to include operational processes that require specialized knowledge and expertise, their focus on developing customized solutions. "We also integrate designs that combine Aluminium and Magnesium," he adds.

To develop solutions with Magnesium, the company provides clients' design teams with comprehensive support that encompasses planning, concept development, execution and ongoing guidance in a fully customized process. The challenges associated with Magnesium alloy production costs are carefully managed, particularly since saving even a single kilogram can translate into additional flight hours, effectively offsetting costs through operational efficiencies.

Transforming Raw Magnesium into High-Performance Alloys "It should be noted that we import raw materials from companies in the US and UK. They buy most of the ore needed for their production from Israel (Dead Sea), says Cohen.

The company has three primary production processes with which to customize the alloy to each client's application. One is machining from plates and rods, a relatively costly process with inherent limitations in production speed and geometric complexity. Another is Magnesium investment casting; one of the world's most precise techniques, it delivers exceptional accuracy even with thin-walled components, allowing an accurate shell, including complementary machining and the creation of complex form. The third method, still in its early stages, is magnesium forging. Its key advantages are significant material savings, increased final product strength and the ability to produce concave shapes with substantial volume in a relatively short time.

"We've also developed a range of Magnesium coating processes, some of them patented, and we plan to integrate in-house painting solutions in the near future," says Cohen. "To build confidence in Magnesium alloys and highlight their advantages, we provide comprehensive support to our clients, reflecting our culture of excellence and rigorous quality control. We take a forward-looking approach to the entire supply chain and proactively address potential challenges. Our CTO and product engineers work closely with clients to monitor production lines, implement updates and deliver real-time solutions, continuously adapting new technologies to minimize operational issues and ensure precise, optimized production management."

Impact on the Local Supply Chain and Knowledge Growth
"Our key advantages include the ability to meet the challenges of importing products at the high standards we achieve both locally and globally, as well as developing innovative, market-disrupting solutions in the Magnesium industry.", according to Cohen. "Israeli companies that successfully adopt these technologies gain recognition and attract interest from major international partners. Another key advantage is being fully vertically integrated, from concurrent engineering and purchasing of raw materials to completed products, with full control over all development and manufacturing stages — a true one-stop-shop that adheres to AS9100 quality standards."

Digitization, automation, artificial intelligence and smart manufacturing — trends that are reshaping Israel's defense industry — are a central Aero-Magnesium focus. "We're at the forefront of this transformation," says Cohen. "We've recently implemented a new ERP system to manage production floors, and we've introduced Industry 5.0 solutions, enabling real-time monitoring, waste reduction and operational improvements at industrial scale.

"Alongside advanced automation, we recognize that people remain a critical asset," he continues. "We place strong emphasis on human capital development — including the training, retention and recruitment of skilled technicians and engineers — while simultaneously investing in robotics and collaborating with research institutes to drive innovation in the Magnesium sector and build manufacturing capabilities that ensure we remain leaders in this evolving smart industry."

Contributing to Israel's Export Strength and Engineering Reputation
Aero-Magnesium's contribution is evident from the enthusiastic feedback from overseas clients, experiencing its lightweight components and high-quality finishes. "Our solutions are more relevant than ever, in light of the wars that Israel and Ukraine have been fighting and with the decision of the US president to position his country as a global drone power," says Cohen. "This creates high demand and increased drone production volume — efforts which require substantial investment and careful risk management but also present significant opportunities for expansion into international markets. With a strong sense of mission and Israeli pride, we're strategically globally positioned. We operate a front office in the US - the State of Alabama, and are growing our activity in the Europe.

Managing the Significant Increase in Demand during the Past Two Years
"We worked around the clock through the conflicts with Hamas and Iran, driven by a sense of mission and the company's culture of excellence," says Cohen. "Our workforce understands the critical importance of what we do. They know that every production line contributes to aircraft components, supports our soldiers and serves sensitive projects whose results speak for themselves. The past two years have underscored the necessity for Israeli industries to operate at peak efficiency. This, it must be said, is an area where the state could do more, allocating resources and supporting processes that ultimately add value to the country and to industries vital for both routine operations and emergency readiness."

In collaboration with Aero-Magnesium

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